Flex-fitting cable tray

ABSTRACT

A cable tray system including two or more cable tray sections comprising a first side rail and a second side rail arranged substantially parallel to one another and a floor extending between. The tray system also includes one or more flex-wires for joining the cable tray sections, where the flex-wires can be U- or loop-shaped. Upon exerting tension on the flex-wires, the first and second cable tray sections can move away from one another from a first position to a second position. In addition, the tray system includes a fastening device that removably locks the tray system into the second position.

BACKGROUND

The present disclosure relates to cable tray systems for use withelectrical and other cable and wiring systems.

Cable trays are used to support cables, electrical wires and the likewhich run through, over, and around buildings. Cable trays may have bothstraight and curved (horizontal and/or vertical) sections to accommodatethe installation requirements of particular settings. There is a needfor straight and curved sections to have flexibility to accommodate evenmore installation requirements.

SUMMARY OF THE DISCLOSURE

One aspect of the disclosure is directed to a cable tray systemcomprising two or more rigid cable tray sections coupled by one or moreflex-wires. In some embodiments the cable tray system of claim furthercomprises a removable fastening device coupled to the two or more cabletray sections to minimize flexibility of the two or more cable traysections, relative to one another, when coupled. In some embodiments,one or more cable tray sections, each cable tray section comprising afirst side rail and a second side rail arranged substantially parallelto one another and a floor extending between and connecting the firstand second side rails. The cable tray system also comprises one or moreflex-wires for coupling joining the cable tray sections. In someembodiments, the flex-wire can be a U-shaped flex-wire extending alength, L, wherein a first leg of the U-shaped flex-wire is coupled to afirst cable tray section and wherein a second leg of the U-shapedflex-wire is coupled to a second cable tray section. In otherembodiments, the flex-wire is a loop-shaped flex-wire, wherein a firstside of the loop-shaped flex-wire is coupled to a first cable traysection and wherein a second side of the loop-shaped flex-wire iscoupled to a second cable tray section. In other embodiments, theflex-wire can be shaped in other manners, including, but not limited toa V or W shape. The cable tray system is configured such that uponexerting tension on the flex-wires, the first and second cable traysections move away from one another from a first position to a secondposition.

In some embodiments, the cable tray system further comprises a removablefastening device that locks the tray system into the second position. Inother embodiments, the first leg of the U-shaped flex-wire is coupled toa first cable tray section by one of a weld or a looped end of the firstleg and wherein a second leg of the U-shaped flex-wire is coupled to asecond cable tray section by one of a weld or a looped end of the secondleg. In other embodiments, the first leg of the loop-shaped flex-wire iscoupled to a first cable tray section by one of a weld or a loopedportion of the first leg and wherein a second leg of the loop-shapedflex-wire is coupled to a second cable tray section by one of a weld ora looped portion of the second leg.

In some embodiments, each cable tray section has one or more sidewallsextending vertically upward or downward from, and generallyperpendicularly to, the floor of the cable tray section. Similarly, eachflex-wire for joining the cable tray sections is bent in an “L” shapethat approximately matches the “L” shape of the bend of the sidewallsfrom the floor of the cable tray section. In other embodiments, the endsof the flex-wires may be bent at other angles less than, or greater than90 degrees. For example, in some embodiments, the legs of the flex-wirescan be bent at approximately 45 degree angles.

In some embodiments, upon exerting tension on the flex-wire, the firstcable tray section moves away from the second cable tray section from afirst position to a second position in one of a substantially upwards,downwards or radial direction. That is, the flex-wires comprise amaterial that is both rigid and bendable. Similarly, in otherembodiments, upon exerting tension on the flex-wire, the first cabletray section moves away from the second cable tray section from a firstposition to a second position in two of a substantially upwards,downwards or radial direction.

BRIEF DESCRIPTION OF THE FIGURES

These and other features, aspects and advantages of the disclosure willbecome more fully apparent from the following detailed description,appended claims, and accompanying drawings, wherein the drawingsillustrate features in accordance with exemplary aspects of thedisclosure, and wherein:

FIG. 1 is a top level perspective view of a cable tray system accordingto one aspect of the disclosure;

FIG. 2A is a top level perspective view of a cable tray system in afirst position according to one aspect of the disclosure;

FIG. 2B is a top level perspective view of a cable tray system withportions in a rigid second position according to one aspect of thedisclosure;

FIG. 3A is an isometric view of a cable tray system in a first positionaccording to one aspect of the disclosure;

FIG. 3B is an isometric view of a cable tray system in a second positionaccording to one aspect of the disclosure;

FIG. 4 is a top level perspective view of a cable tray system accordingto one aspect of the disclosure;

FIG. 5 is a is an isometric view of a cable tray system according to oneaspect of the disclosure;

FIG. 6A is a bottom front view of a cable tray system according to oneaspect of the disclosure; and

FIG. 6B is a front view of a cable tray system in a second, rigidposition according to one aspect of the disclosure;

DETAILED DESCRIPTION

The accompanying figures and this description depict and describeaspects of a cable conveyance system in accordance with the presentdisclosure, and features and components thereof. It should also be notedthat any references herein to front and back, right and left, top andbottom, iso or isometric, upper and lower are intended for convenienceof description, not to limit the present invention or its components toany one positional or spatial orientation.

Before any aspects of the disclosure are explained in detail, it will beunderstood that the disclosure is not limited in its application to thedetails of construction and the arrangement of components set forth inthe following description or illustrated in the following drawings. Thedisclosure is capable of other aspects and of being practiced or ofbeing carried out in various ways. Also, it will be understood that thephraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. All numbers expressing measurements and soforth used in the specification and claims are to be understood as beingmodified in all instances by the term “about.”

Various aspects of the present disclosure are directed to a cableconveyance system for routing cables. With reference to FIGS. 1-6, anaspect of a flex-fitting tray system 10 is described in detail. As shownin FIG. 1, flex-fitting tray system 10 includes two or more traysections 20 a and 20 b, each having a floor 22 on which cables routedthrough the system will rest. At least a portion of each floor 22 issubstantially horizontal. While two tray sections 20 a and 20 b aredepicted, in some embodiments the flex-fitting tray system 10 comprisesmultiple tray sections 20 a, 20 b.

Each tray section 20 a or 20 b further comprises a first side rail 12 aand second side rail 12 b. In some embodiments, the side rails 12 a and12 b are spaced apart by a population of transverse rungs 16 extendingbetween the first and second side rails 12 a, 12 b. In otherembodiments, the side rails 12 a and 12 b are spaced apart by one ormore plates (not shown). While not shown, it will be understood thatflex-fitting tray system 10 may be installed on other types and/orconstruction of cable trays.

The population of transverse rungs 16 are spaced at intervals along thelength of first and second side rails 12 a, 12 b, forming a ladder-likestructure. In some embodiments, the rungs are spaced 2 inches from oneanother, while in other embodiments, the rungs may be spaced closer toone another (i.e., less than 2 inches), or further apart from oneanother (i.e., greater than 2 inches). In some embodiments, the rungs 16are 4 inches wide, thus spacing the rails 12 a and 12 b approximately 4inches from one another, however, the rungs can be wider or less wide,depending upon the desired dimensions of each tray section 20 a or 20 b.In some embodiments, wires or cables will lay length-wise in the trayssystem 10, such that they lay upon the side rails 12 a, 12 b.

In some embodiments, the tray sections 20 a and 20 b further compriseend pieces 25 a and 25 b that are affixed approximately parallel to therungs 16. In some embodiments, the end pieces are curved or bent toaccommodate and/or to provide further support for the cables. In someembodiments, end pieces 25 a and 25 b are spaced at a closer distance tothe closest rung 16, such that the spacing is approximately the same asthe spacing of the rungs 16, in other embodiments, end pieces 25 a and25 b are spaced at a further distance or a closer distance than thespacing of rungs 16.

Cable and electrical wires placed in the cable tray system 10 typicallyrest on the floor 22 of tray sections 20 a and 20 b.

Rungs 16 may be tack welded to first and second side rails 12 a, 12 b onone or more sides of rungs 16, for example, at locations A and B.Additionally, rungs 16 may be welded to first and second side rails 12a, 12 b at a plurality of locations along rails 12 a and 12 b. In someembodiments, rungs 16 are welded to the undersides of rails 12 a and 12b. In other aspects, for example, rungs 16 may be mechanically fastenedto first and second side rails 12 a, 12 b in a variety of waysincluding, but not limited to, screws, bolts, rivets, etc. instead of orin addition to welding.

The first and second side rails 12 a, 12 b and the transverse rungs 16are preferably constructed of steel or an alloy thereof; however, itwill be understood that any type of suitable material may be used,including, but not limited to, plastics, aluminum, stainless steel, oralloys thereof. First and second side rails 12 a, 12 b and transverserungs 16 may be formed by extruding, casting, bending, or any other typeof forming known in the art.

The two or more tray sections 20 a and 20 b of flex-fitting tray system10 are coupled to one another or joined to one another using one or moreflex-wires 50. In some embodiments, flex-wire 50 is in an elongatedu-shape. In other embodiments, flex-wire 50 can have an elongated ovalor square-like shape. As shown in FIG. 1, some embodiments can havemultiple tray sections 20, each attached to one another by one or moreflex wires 50. As such, the flex-fitted tray system is customizable.

The flex-wires 50 are flexible such that they enable the tray sections20 a and 20 b to be bendable and/or moveable away from one another in ahorizontal, vertical and/or radial direction. The flex-wires 50 arepreferably constructed of a bendable material such as steel; however, itwill be understood that any type of suitable material may be used,including, but not limited to, plastics, aluminum, stainless steel oralloys thereof. At the same time, flex-wires 50 are rigid such that theymaintain the positions of the tray sections.

In some embodiments, flex-wires 50 are generally U-shaped and extend alength, L, wherein a first leg of the U-shaped flex-wire 50 is fastenedto a first cable tray 20 a and wherein a second leg of the flex-wire 50is fastened to a second cable tray 20 b. Fastening, as used herein, canbe by any means, including but not limited to welding, gluing, ormechanically affixing means. In other embodiments, the flex-wires 50 canbe shaped in other manners, including, but not limited to a V or Wshape.

As illustrated in FIG. 1, in some embodiments, flex-wire 50 is fastenedto one or more parts of a second side rail 12 b of a first tray section20 a (at location X) and/or fastened to one or more parts of a firstside rail 12 a of a second tray section 20 b (at location Y). In otherembodiments, the end portion of the legs of flex-wires 50 can be bent atthe ends at approximately a 90 degree angle, and the bent portion of theends can then be fastened to one or more rungs 16, while additionallyand/or alternatively the unbent leg portion can be fastened to one ormore parts of a side rail 12 a.

In other embodiments, and with reference to the dashed line in FIG. 1,the end portion of the legs of flex-wires 50 can be bent at the ends atapproximately a 90 degree angle and the bent portions can be continuousfrom one flex wire 50 to the next adjacent flex wire 50, such that the90 degree leg portion forms a rung 16 between the two side rails 12 aand 12 b. In other embodiments, not shown, flex-wire 50 is temporarilyaffixed to side rails 12 a and 12 b using a fastening device 60. Inother embodiments, described herein, one or more of the legs of theflex-wire 50 couples to one or more of side rails 12 a and 12 b byhooking around the rails.

Also with reference to FIG. 1, in some embodiments, two or more traysections 20 a and 20 b may be joined together by a common side rail 12,and not include any flex-wires 50 connecting the tray portions. In thosesuch embodiments the two or more tray sections 20 a and 20 b may not bemoveable in relation to one another.

As shown in FIG. 2a , in some embodiments, the primary tray sections 20a and 20 b further includes one or more sidewalls 24 a and 24 bextending upwardly from and/or downwardly from, and generallyperpendicularly to, the floor 22. For example, in some embodiments, thesidewalls 24 a and 24 b are portions of the floor 22 that have been bentvertically upward or downward from the horizontal plane of the floor 22.

For embodiments in which the primary tray sections 20 a and 20 b furtherinclude one or more sidewalls 24 a and 24 b extending vertically upwardor downward from, and generally perpendicularly to, the floor 22,flex-wires 50 can be bent in an “L” shape that approximately matches the“L” shape of the bend of the sidewalls 24 a and 24 b from the floor 22.In other embodiments, the ends of the flex-wires may be bent at otherangles less than, or greater than 90 degrees. For example, in someembodiments, the legs of the flex-wires can be bent at approximately 45degree angles.

With reference to FIG. 2B, because flex-wires 50 a and 50 b areflexible, primary tray section 20 a is moveable and/or bendable awayfrom tray section 20 b. That is, flex-wires 50 a and 50 b enable traysection 20 a to be pulled apart from tray section 20 b and rotatedupwards or downwards from the same horizontal plane as tray section 20b.

With reference to one embodiment illustrated in FIG. 3A and FIG. 3B,flex-wires 50 a and 50 b can be used to move tray sections 20 a and 20 baway from one another in a radial direction. For example, in someembodiments, flex-wire 50 b may be pulled so that tray sections 20 a and20 b rotate radially outward from the axis created by the intersectionof the inverted “U” of flex-wire 50 a, and the floor 22 formed by traysections 20 a and 20 b. In some embodiments and with reference to FIG.3B, flex-wires 50 a can be moved radially outwardly away from eachother, while flex wires 50 b can be moved radially inwardly towardsanother such that the tray sections 20 can be moved away from oneanother. In some embodiments, depending upon the direction of forceexerted on flex-wires 50 a or 50 b, tray sections 20 can also be movedaway from the horizontal plane defined by the floor 22 and/or from thevertical plane defined by the side wall 24 a. In other embodiments (notshown), the welds at location A and B in FIG. 3A may be cut using a boltcutter or other similar device such that only flex-wire 50 b, and notflex-wire 50 a, remains attached to tray sections 20 a and 20 b, andthus bending of flex-wire 50 b only causes the tray sections 20 to moveaway from one another.

While FIGS. 2a, 2b, 3a and 3b show embodiments with multiple flex-wires,in some embodiments, flex-fitting tray systems 10 comprise a singleflex-wire 50 coupled to tray sections 20 a and 20 b. For example, withreference to FIG. 4, flex-fitting tray system 10 comprise tray sections20 a and 20 b coupled to one another by a single, oval-like flex-wire50. FIG. 4 additionally contains additional tray sections coupled byadditional flex-wires.

As illustrated in FIG. 5, single flex-wires 50 can also be used in traysystems 10 that have one or more bends in the trays portions 20 a and 20b. In embodiments illustrated in FIGS. 4 and 5, a first side of theloop-shaped flex-wire 50 is fastened to a first cable tray and a secondside of the loop-shaped flex-wire 50 is fastened to a second cable tray.The sides of flex-wire 50 can be fastened in one or more locations totray portions 20 a and 20 b.

With reference to FIG. 6A, in some embodiments, one or more of the legsof flex-wire 50 is shaped as a loop to couple to a side rail 12 b or 12a to help secure the flex-wire 50 to the tray sections 20 a and 20 b. Insome embodiments, the legs of flex-wire 50 (U, V, W or otherwise shaped)can be additionally fastened to side rails 12 a and 12 b and/or fastenedto one of the side rails 12 a, and looped around other side rail 12 busing loop 55. In other embodiments, the legs of flex-wire 50 can belooped around both side rails 12 a and 12 b using loops 55.

In other embodiments, with reference to FIGS. 6A and 6B, one or morefastening devices 60 can help keep flex-wire 50 rigid where needed, forexample, where it is coupled to tray sections 20 a and 20 b in aremovably lockable manner. In other embodiments, the flex-wires 50 canbe coupled to side rails 12 a and/or 12 b, rungs 16, end pieces 24Aand/or 24 b by welding or some other fastening means. In someembodiments, due to the curved flange portions 65 a, b, and/or c offastening device 60, fastening device 60 can hook onto side rails 12 aand/or 12 b, rungs 16, end pieces 24A and/or 24 b, and/or flex-wires 50.In other embodiments, fastening device has only one or two flangeportions 65, such as on the sides of the fastening device 60, but notalong the top end of fastening device 60. In some embodiments, whereflex-wire 50 does not include a loop 55, fastening devices 60 can befurther secured to side rails 12 a and/or 12 b, rungs 16, end pieces 24Aand/or 24 b, and/or flex-wires 50 with a pair of pliers or some othermeans. In some embodiments, fastening devices 60 can be a Faslock clipsold by Cablofil, including, but not limited to a Faslock Auto clip, aFaslock Auto S clip, and/or a Faslock Auto XL clip. Fastening device 60can be made of electrozinc, hot dip galvanized, stainless steel 316L orother suitable metal or plastic materials. Fastening devices 60 areremovably lockable and can be released from tray system 10 by twistingthem or using pliers or some other means.

In some embodiments, fastening device 60 is positioned on the internalangle of a radius bend after flex-wire 50 has been cut or bent and trayportion 20 a has been radius away from tray portion 20 b (not shown). Insuch cases, fastening device 60 locks the tray system 10 into a rigidsecond position.

Thus, there has been shown and described a novel cable tray systemincluding a flexible-wire, which overcomes many of the problems of theprior art. It will be apparent, however, to those familiar in the art,that many changes, variations, modifications, and other uses andapplications for the subject devices and methods are possible. All suchchanges, variations, modifications, and other uses and applications thatdo not depart from the spirit and scope of the disclosure are deemed tobe covered by the disclosure which is limited only by the claims whichfollow.

What is claimed is:
 1. A cable tray system comprising: two or more rigidcable tray sections coupled by one or more flex-wires.
 2. The cable traysystem of claim 1, further comprising a removable fastening devicecoupled to the two or more cable tray sections to minimize flexibilityof the two or more cable tray sections, relative to one another, whencoupled.
 3. The cable tray system of claim 1, wherein each cable traysection comprises: (A) a first side rail and a second side rail arrangedsubstantially parallel to one another and a floor extending between andconnecting the first and second side rails; (B) one or more flex-wiresfor joining the cable tray sections, wherein the flex-wires eachcomprise: (i) a flex-wire extending a length, L, wherein a first leg ofthe flex-wire is coupled to a first cable tray section and wherein asecond leg of the flex-wire is coupled to a second cable tray section;wherein, upon exerting tension on the flex-wires, the first and secondcable tray sections move away from one another from a first position toa second position.
 4. The cable tray system of claim 3, furthercomprising a removable fastening device that locks at least a portion ofthe cable tray system into the second position, keeping at least aportion of the cable tray system from the first position.
 5. The cabletray system of claim 3, wherein the first leg of the flex-wire iscoupled to a first cable tray section by one of a weld or a looped endof the first leg and wherein a second leg of the flex-wire is coupled toa second cable tray section by one of a weld or a looped end of thesecond leg.
 6. The cable tray system of claim 3, wherein each of thecable tray sections has one or more sidewalls extending verticallyupward or downward from, and generally perpendicularly to, the floor ofthe cable tray sections.
 7. The cable tray system of claim 6, whereinthe ends each of the flex-wires for joining the cable tray sections isbent in one of an “L” shape that approximately matches the “L” shape ofthe bend of the sidewalls from the floor of the cable tray sections or a45-degree angle that does not match the “L” shape of the bend of thesidewalls from the floor of the cable tray sections.
 8. The cable traysystem of claim 1, wherein each of the flex-wires comprises a materialthat is bendable.
 9. The cable tray system of claim 1, wherein uponexerting tension on the flex-wire, the first cable tray section movesaway from the second cable tray section from a first position to asecond position in one of a substantially upwards, downwards and radialdirection, or any combination of upwards, downwards or radial direction.10. The cable tray system of claim 1, wherein upon exerting tension onthe flex-wire, the first cable tray section moves away from the secondcable tray section from a first position to a second position in two ofa substantially upwards, downwards, and radial direction or anycombination of upwards, downwards and radial direction.
 11. The cabletray system of claim 2, wherein the first leg of the flex-wire iscoupled to the first cable tray section by a looped end of the first legthat encircles a portion of the first cable tray section.
 12. The cabletray system of claim 1, wherein the one or more flex-wires are one ofU-, V- or W-shaped.
 13. A cable tray system comprising: two or morerigid cable tray sections coupled by one or more loop-shaped flex-wires.14. The cable tray system of claim 13, further comprising a removablefastening device coupled to the two or more cable tray sections tominimize flexibility of the two or more cable tray sections, relative toone another, when coupled.
 15. The cable tray system of claim 13,wherein each cable tray section comprises: (A) two or more cable traysections, each of the cable tray sections comprising a first side railand a second side rail arranged substantially parallel to one anotherand a floor extending between and connecting the first and second siderails; (B) one or more flex-wires for coupling the cable tray sectionsto one another, wherein the flex-wires each comprise: (i) a loop-shapedflex-wire, wherein a first side of the loop-shaped flex-wire is fastenedto a first cable tray section and wherein a second side of theloop-shaped flex-wire is fastened to a second cable tray section;wherein, upon exerting tension on the flex-wires, the first and secondcable tray sections move away from one another from a first position toa second position.
 16. The cable tray system of claim 15, furthercomprising a removable fastening device that locks at least a portion ofthe cable tray system into the second position, keeping at least aportion of the cable tray system from the first position.
 17. The cabletray system of claim 15, wherein the first leg of the loop-shapedflex-wire is coupled to a first cable tray section by one of a weld or alooped portion of the first leg and wherein a second leg of thelooped-shaped flex-wire is coupled to a second cable tray section by oneof a weld or a looped portion of the second leg.
 18. The cable traysystem of claim 15, wherein each of the cable tray sections has one ormore sidewalls extending vertically upward or downward from, andgenerally perpendicularly to, the floor of the cable tray sections. 19.The cable tray system of claim 18, wherein the ends of each of theflex-wires for joining the cable tray sections is bent in one of an “L”shape that approximately matches the “L” shape of the bend of thesidewalls from the floor of the cable tray sections or a 45-degree anglethat does not match the “L” shape of the bend of the sidewalls from thefloor of the cable tray sections.
 20. The cable tray system of claim 13,wherein upon exerting tension on the flex-wire, a first cable traysection moves away from a second cable tray section from a firstposition to a second position in one of a substantially upwards,downwards and radial direction, or any combination of upwards,downwards, and radial direction.
 21. The cable tray system of claim 13,wherein upon exerting tension on the flex-wire, a first cable traysection moves away from a second cable tray section from a firstposition to a second position in two of a substantially upwards,downwards and radial direction, or any combination of upwards,downwards, and radial direction.
 22. The cable tray system of claim 15,wherein the first leg of the flex-wire is fastened to the first cabletray section by a looped portion of the first leg that encircles aportion of the first cable tray section.